Gema FPS16 Guide

En
Translation of the original operating instructions
Operating instructions and spare parts list
Fresh powder system
FPS16

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Documentation FPS16 Fresh powder system
© Copyright 2005 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is prohib-
ited by law. No part of this publication may be reproduced, photocopied,
translated, stored on a retrieval system or transmitted in any form or by
any means for any purpose, neither as a whole nor partially, without the
express written consent of Gema Switzerland GmbH.
MagicCompact, MagicCylinder, MagicPlus, MagicControl, OptiFlex, Opti-
Control, OptiGun, OptiSelect, OptiStar and SuperCorona are registered
trademarks of Gema Switzerland GmbH.
OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray, Op-
tiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise
Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve
Control (DVC) are trademarks of Gema Switzerland GmbH.
All other product names are trademarks or registered trademarks of their
respective holders.
Reference is made in this manual to different trademarks or registered
trademarks. Such references do not mean that the manufacturers con-
cerned approve of or are bound in any form by this manual. We have en-
deavored to retain the preferred spelling of the trademarks, and registered
trademarks of the copyright holders.
To the best of our knowledge and belief, the information contained in this
publication was correct and valid on the date of publication. Gema Swit-
zerland GmbH makes no representations or warranties with respect to the
contents or use of this publication, and reserves the right to revise this
publication and make changes to its content without prior notice.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
For information regarding patents, visit
www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Fax: [phone]
Email: [email protected]

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FPS16 Table of contents •1
Table of contents
General safety regulations 3
Safety symbols (pictograms)...................................................................................3
Intended use ...........................................................................................................3
Product-specific safety measures...........................................................................4
FPS16 Fresh powder system.....................................................................4
About this manual 5
General information ................................................................................................5
Function description 7
Field of application..................................................................................................7
Overview.................................................................................................................7
Versions.....................................................................................................7
Technical Data 9
FPS16 Fresh powder system..................................................................................9
Conveying performance.............................................................................9
Electrical data ............................................................................................9
Pneumatic data........................................................................................10
Dimensions ..............................................................................................10
Container specifications (big bag) ...........................................................10
Equipment description 11
Structure................................................................................................................11
Support.....................................................................................................12
Lifting device for large containers............................................................12
Fluidizing/suction tube .............................................................................12
Lifting device for fluidizing/suction tube...................................................12
Vibrating plate..........................................................................................12
Control......................................................................................................12
Powder pump...........................................................................................12
Function ................................................................................................................13
Powder flow detection..............................................................................13
Operating and display elements...........................................................................14
Control cabinet.........................................................................................14
Control module.........................................................................................15
Start-up 17
Electrical allocation...............................................................................................17
Main module inputs..................................................................................17
Main module outputs................................................................................17
Additional module inputs..........................................................................18
Additional module outputs........................................................................18
Pneumatic connection...........................................................................................18
Powder connections..............................................................................................18

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2•Table of contents FPS16
Start-up................................................................................................................. 19
Parameterization .................................................................................................. 19
The standard display looks as follows:.................................................... 19
Parameter input display:.......................................................................... 19
Entering and selecting a menu option..................................................... 20
Powder flow detection .......................................................................................... 22
Overview.................................................................................................. 22
Procedure description.............................................................................. 23
Adjusting the threshold values ................................................................ 23
Container change / color change / cleaning 25
Container change................................................................................................. 25
Color change ........................................................................................................ 25
Cleaning................................................................................................................ 26
Maintenance 27
General information.............................................................................................. 27
Troubleshooting 29
General information.............................................................................................. 29
Spare parts list 31
Ordering spare parts............................................................................................. 31
FPS16 Fresh powder system –spare parts list.................................................... 32
FPS16 Fresh powder system –spare parts......................................................... 33
Fluidizing/suction tube.......................................................................................... 34
Fluidizing/suction tube.......................................................................................... 35
Control.................................................................................................................. 36
Control.................................................................................................................. 37
Pinch valve ........................................................................................................... 38

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FPS16 General safety regulations •3
General safety regulations
This chapter sets out the fundamental safety regulations that must be fol-
lowed by the user and third parties using the FPS16 Fresh powder sys-
tem.
These safety regulations must be read and understood before the Fresh
powder system is put into operation.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
Switzerland operating instructions. The general safety precautions must
also be followed as well as the regulations in the operating instructions.
DANGER!
danger due to live electricity or moving parts Possible consequences:
Death or serious injury
ATTENTION!
Improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: minor injuries or damage to equip-
ment
NOTE:
Useful tips and other information
Intended use
–The Fresh powder system is state of the art equipment that con-
forms to the recognized technical safety regulations and is designed
for normal powder coating applications.
–Any other use is not considered as intended use. The manufacturer
shall not be liable for damage resulting from such use; the user
bears sole responsibility for such actions. If the Fresh powder sys-
tem is to be used for other purposes or other substances outside of
our guidelines, then Gema Switzerland GmbH should be consulted.
–Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended use. The
Fresh powder system should only be used, maintained and started
up by trained personnel informed and familiar with the possible haz-
ards involved.

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4•General safety regulations FPS16
–Start-up (i.e. operation of its intended use) is not allowed until it has
been established that the Fresh powder system has been installed
and wired according to the EU Machinery Directive (2006/42/EC).
EN 60204-1 (machine safety) must also be observed.
–Unauthorized modifications to the Fresh powder system exempt the
manufacturer from any liability from resulting damage.
–The relevant accident prevention regulations, as well as other gen-
erally recognized safety regulations, occupational health and struc-
tural regulations are to be observed.
–Furthermore, the country-specific safety regulations also must be
observed.
Explosion protection
Protection type
II 3D
IP54
Product-specific safety measures
–Installation work performed by the customer must be carried out ac-
cording to local regulations.
–All components must be grounded according to the local regulations
before start-up.
–Due to accident risk and depending on the placement of the fresh
powder system, the safety barriers have to be placed in accordance
to the local regulations!
–The big bag equipped with antistatic loops is grounded via the FPS
hang-up plate.
–Grounding resistance should be checked regularly and should not
exceed 108ohm.
–If the big bag is detached from the hang-up plate, ensure that it is
appropriately grounded, as friction charging may occur during trans-
ferring processes.
FPS16 Fresh powder system
The Fresh powder system is part of the plant and therefore integrated in
the safety concept of the plant.
If it is to be used in a manner outside the scope of the safety concept,
then corresponding measures must be taken.
NOTE:
For further information, see the more detailed Gema safety regula-
tions!

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FPS16 About this manual •5
About this manual
General information
This operating manual contains all important information which you re-
quire for the working with the Fresh powder system. It will safely guide
you through the start-up process and give you references and tips for the
optimal use of your new powder coating system.
Information about the function mode of the individual system components
–booth, gun control unit, manual gun or powder injector –should be ref-
erenced to their corresponding documents.
DANGER:
Working without operating instructions
Working without operating instructions or with individual pages
from the operating instructions may result in damage to property
and personal injury if relevant safety information is not observed.
►Before working with the device, organize the required documents and
read the section on "Safety regulations".
►Work should only be carried out in accordance with the instructions in
the relevant documents.
►Always work with the complete original document.

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FPS16 Function description •7
Function description
Field of application
The FPS16 Fresh powder system is built exclusively for electrostatic coat-
ing with organic powders. Any other use is not considered as intended
use. The manufacturer is not responsible for any incorrect use and the
risks associated with such actions are assumed by the user alone.
Overview
The Fresh powder system is suited for supplying the powder coating
equipment with powder from large containers (Big Bag). The powder sup-
ply takes place continuously from the large container and in accordance
to the consumption in the coating plant. The powder transport is automat-
ically switched on and off by messages from the level sensor in the pow-
der container. The powder is aspirated in pulses by a vacuum, and sub-
sequently transported with conveying air.
Versions
The FPS16 Fresh powder system is available either with one or with two
powder pumps (FPS16-2). The FPS16-2 version permits a powder
transport from the large powder container to two different destinations.
FPS16-1 FPS16-2